US2384123A - Unsaturated carbonate esters and polymers thereof - Google Patents

Description

mama Sept. 4,1945

' U ITED STATES PATENT OFFICE unssroas gz ifigsm agms AND Irving a. Muskat, Akron, and lh-anklin Strain.

Norton Center, Ohi

o, assignors to Pittsburgh Plate Glass Company, Pittsburgh, Pa., a corporation of Pennsylvania No Drawing. Application March 7, 1942,

Serial No. 483,829

9 Claims. (Cl. zoo-rs) This invention relates to a new class of unsaturated esters having unusual properties which render them valuable invarlous chemical arts.

Because of the indefinite scope and variation in the common usage of. certain chemical expressions, it is necessary to define and limit such expressions which are used in the following specification and claims.

By all "polyhydroxy compounds we mean compounds having twoor more hydroxy groups which do not contain any free acid groups. These polyhydroxy compounds may have ether, thioether, amino, amido, or ester linkages between the reactive hydroly groups. By ester linkages we mean a linking oxygen atom derived from the reaction between an acid and an alcohol. Thus, a carbonate R-O-CO-O-R con talns two ester linkages.

By simple polyhydroxy compounds" we mean polyhydroxy compounds which do not contain ester linkages between the. reactive hydroxy groups such as resorcinol, ethylene glycol, glycerine, etc. Polvhydroxy ethers such as diethylene glycol or tripropylene glycol and the corresponding thio ethers are considered to be simple polyhydron compounds. The polyhydroxy compounds which contain ester linkages between the reactive hydroxy groups such as ethylene glycol monolactate (OH)-CsHeCOCH(OH)-CH:, diethylene glycol diglycolate and castor oil are not considered to be within the scope of the term simpl polyhydroxy compound" due to the presence of one or more ester linkages between the hydroxy groups in such compounds.

The invention is'particularly directed to esters of unsaturated alcohols having up to five carbon atoms in the molecule such as allyl, methallyl. crotyl, isocrotyl, roparsyl, methyl ethynyl carbinyl, methyl vinyl carblnyl, tiglyl, angelyl, methyl allyl carbinyl or ethylallyl alcohols. The halogen substituted products of the above alcohols glycerol, alpha methyl glycerol, mannitol, erythritol, pentaerythritol, pinacol, dextrose, lactose. sucrose, starch, cellulose, polyvinyl alcohols, etc., or the halogen or amino, nitro, or other hydrogen substituted derivatives thereof.

A preferred group of these new unsaturated esters are those in which all of the hydroxyl groups of the polyhydrom' compound are esterified with the half ester of carbonic acid and the unsaturated alcohols. These neutral esters may be represented by the general formula in which R is a saturated aliphatic hydrocarbon radical having a valence of :r,-R1- is the radical derived from an unsaturated alcohol, and a: is a small whole number greater than two and less than seven. These esters contain the radical of only a single molecule of the simple polyhydroxy tion of an unsaturated chlorofor'mate such as allyl, or methallyl chloroformate with the polyhydroxy compound. The esters may also be prepared by reaction of the poiyhaloformates of the p hydroxy compound such as glycerol trichloroformate with the unsaturated alcohol. In-

ates, etc., with the chloroformates of unsaturated alcohols. The same mixed esters may also be prepared by treating thehydroxy ester of a simple polyhydroxy compound with phosgene to form a polychloroformate which may then be reacted with an unsaturated alcohol.

In allpreparations the chloroformates are first 1 made by treating the hydroxy compound with phosgene at low temperatures, preferably between 1 0' C. and 20' C. The chloroformates are then added slowly to the alcohol or polyhydroxy compound also at temperatures between 0' C. and 20' O. and in thepresence of an alkaline reagent such as pyridine or other cyclic tertiary amine or the oxides, carbonates. or hydroxides of sodium, potassium, barium, calcium, magnesium. or

other metal. Inert diluents or solvents such'as acetone, chloroform, benzene, water, etc., may be .chloride and petroleum ether.

added to assist the reaction. The resulting product may be purified by washing with dilute acid and/or dilute salt solutions, for example, sodium carbonate and sodium chloride solutions, and/or water. The washed products may be freed of volatile impurities by topping (i. e.) heating with or without vacuum to distil off the more volatile impurities. Frequently, the boiling point of the ester is suiliciently low to permit a fractional distillation at reduced pressures.

The new unsaturated carbonates are generally non-resinous compounds having distinct boiling and melting points and are often capable of separation in substantially pure state. Frequently, the impurities are side reaction products which are colorless and transparent esters having characteristics similar to the esters herein contemplated. In such cases, removal of such impurities may be unnecessary where they do not produce any detrimental effect in the use to which the ester is put. The new compounds are usually liquids at room temperature but some, however, are solids. The new unsaturated compounds are usually miscible with solvents such as benzene, toluene, chloroform, diethyl ether, carbon tetra- The monomeric esters are valuable as plasticizers for various resin materials such as styrene, cellulose, vinyl, urea, protein, phenolic, or acrylic resins. Other uses such as solvents, insecticides, and liquid coating compositions are noteworthy.

in which substantially all of the polymer is substantially infusible and substantially insoluble in organic solvents, acids, and alkalies.

The monomers of the polyunsaturated esters may be cast polymerized directly to the substantially insoluble, infusible state. This procedure is subject to certain inherent difificulties due to the strains which are established during polymerization of the gel and which frequently result in fractures as the final hard form is attained. It has been discovered that these dimculties may be avoided by releasing the strains established in the gel before the fracturing can occur. This may be done by permitting the strains to be relieved before the polymerization is complete, either periodically or by-conducting the polymerization under conditions which permit gradual release of these strains. For example, the poly- These esters may be polymerized in the presintermediate stage and finally to a substantially infusible and/or insoluble form. The completely polymerized polyunsaturated compounds are, in general, substantially unafiected by acids, alkalies, water, and, organic solvents. Intermediate polymers derived from the polyunsaturated esters having a wide range of properties may be secured by incomplete polymerization. The polymers thus obtained are transparent and colorless, although they may at times have a. slightly yellow color,

especially when polymerized completely. Many of these new polymers are generally tougher and more resistant to shattering than are the unsaturated alcohol esters of'polybasic acids.

Upon the initial polymerization of the polyunsaturated esters in liquid monomeric state, or in a solution of the monomer in suitable solvents, an increase in the viscosity of the liquids is noticeable due to the formation of a simple polymer which is soluble in the monomer and in solvents such as acetone, benzene, xylene, dioxane, toluene, or carbon tetrachloride. Upon further polymerization, the liquid sets up to form a soft gel containing a substantial portion of a polymer which is insoluble in the monomer and or anic solvents and containing as well, a substantial portion of a soluble material which may be monomer and/or soluble, fusible polymer. These gels are soft and bend readily. However, they are fr le and crumble or tear under low stresses.

They may be further polymerized in the presence merization may be conducted in a simple mold plete decomposition of the peroxide catalyst. 1

This temperatureis dependent upon the catalyst used. For benzoyl peroxide temperatures of to C. are suitable while for acetone peroxide temperatures of Mil-150 C. may be used. In accordance with'one modification, the gel, after it is freed from the mold, may be coated on both sides with monomer or the syrupy polymer. The coated article is then polymerized between smooth heated plates to the final insolublestate.

In order to inhibit formation of cracks during the initial polymerization, it is frequently desirable to minimize the polymerization on one side of the sheet. This is done by conducting the polymerization with one side exposed to the air which inhibits polymerization in the presence of a peroxide catalyst, such as benzoyl peroxide.

Thus, a sheet is produced which is hard and smooth on one side while being soft and tacky on the other. The sheet may then be finished by coating the tacky side with monomer or syrupy polymer and polymerizing it in contact with a smooth plate to the insoluble, infusible state. Often it is found desirable to release the polymer from the plate one or more times during polymerization of the coating in order to minimize formation of cracks or other surface defects.

Cast polymers may be also' prepared by a single step polymerization directly to the insoluble infusible state. The monomer may be mixed with one ,to five percent of benzoyl or other organic peroxide and heated at 50-60 C. until it becomes partly polymerized and thickened to an increased viscosity of to 1000 percent of the monomer viscosity. The thickened monomer may then be polymerized between glass, metal, or similar plates which are separated by compressible gaskets or retainers of Koroseal (plasticized polyvinyl chloride), butadiene polymers, polyvinyl alcohol, Thiokol (polyethylene sulfide), rubber, or

- similar materials arrangediabout the edge'of such plates. The thickened monomer may be poured on one glass plate within the confines of the flexible retainer, laid about '2 inches from the edge of the plate. The second glass plate may then be carefully laid on top, taking care to avoid the trapping of air bubbles under the top plate. When the top plate is in position, both plates may be held together by means of suitable clamps which are capable of applying pressure upon the plates and are placed directly over the flexible retainer. The entire assembly is then placed in an oven and heated at 70. to 100 C. where the polymerization is continued, During the polymerization the resin shrinks and tends to draw away from the glass surfaces. To prevent fractures pressure is maintained upon the plates to depress the flexible container and permit. the plates to remain in contact with the polymerizing resin. This pressure may be maintained by periodically tightening the clamps or by use of spring clamps which maintains a uniform pressure throughout the polymerization process.

By an alternative procedure for east polymerizing sheets, themolds may be assembled before the thickened monomer is poured. Thus, the flexible compressible retainer may be inserted between the plates and held in place by suitable clamps located around the edge of the plates. This retainer or gasket is placed adjacent the edge of the plates and a suitable opening may be provided between the ends of the flexible retainer, preferably at one corner of the mold. The assembled mold is then placed ina vertical position with the open corner uppermost. The thickened monomer containing one to four percent residual peroxide is then poured in slowly until the enin the fusible polymer and the monomer. Thistire mold is filled. After standing until all of it is separated from the glass plates and a hard,

transparent, colorless and durable resin sheet is obtained.

Other methods have been developed for polymerization of the compounds herein contemplated while avoiding formation of cracks and fractures. By one of these methods the polymerization may be suspended while the monomerpolymer mixture is in the liquid state and before the polymer is converted to a gel by cooling, re-'- moval from exposure to ultraviolet light, by adding inhibiting materials such as'pyrogallol, hydroquinone, aniline, phenylene diamine, or sulphur, or by destruction of the polymerization catalyst. The fusible polymer may be separated from all or part of the monomer by any of sev-' eral methods. It may be precipitated by the addition of nonsolvents for the fusible polymer such as water, ethyl alcohol, methyl alcohol, or glycol. Alternatively, it may also be separated from the monomer by distillationin the presence of an inhibitor for polymerization and preferably at reduced pressures. The fusible polymer is thus obtained in stable solid form and as such may be used as a molding powder or may be redissolved in suitable solvent for use in liquid form. It is soluble in organic solvents which are normally capable of dissolving methyl methacrylate polymer or similar vinyl type polymer. Preferably, the polymers of the new esters are produced by heating the monomer or a solution thereof in the presence of substantial quantities, forexample,

' 2 to 5 percent of benzoyl peroxide until the viscosity of the solutionhas increased about 100 ,to 500 percent. This may require from one-half to two hours while heating at 65 to 85 C., in the presence of benzoyl peroxide. The resulting viscous solution is poured into an equal volume of water, methyl or ethyl alcohols, glycol orother non-solvent for the fusible polymer. usually in the form of a powder or a gummy precipitate is thus formed which may be filtered and dried. This permits substantially complete separationof 'asoluble fusible polymer from unpolymerized monomer.

Often, however, such complete separation is not desirable since hazy products may be secured upon further polymerization. Accordingly, it is often desirable to produce compositions comprismay be effected by partial distillation or extraction of monomer from the polymer or by reblending a portion of the fusible polymer with the same or a different polymerizable monomer. In general, the composition should contain at least '40 percent and preferably in excess of 50 percent -fusible polymer and from about 5 percent to 50 or 60 percent monomer.

Preferably, the production of these materials is conducted by treatment of a solution of the monomer in a solvent for monomer'and polymer such as benzene, xylene,-to1uene, carbon tetrachloride, acetone, or other solvent which normally dissolves vinyl polymers.

Other polymerization methods may involve the interruption of the polymerization while the polymer is a gel. For example, a soft solid gel containing a substantial portion of fusible polymer may be digested with a quantity of solvent for the fusible polymer to extract the fusible gel from the infusible. The solution may then be treated as above described to separate the fusible polymer from the solvent. These polymers may be used as molding or coating compositions. Due to their solubility, they are particularly desirable for use in paint compositions.

Other fusible polymers may be prepared by carrying the initial polymerization to the point where the polymer is in the form of a gel which generally contains at least 20 percent and pref,- erably about 45 to percent by weight of substantially insoluble polymer, but at which point the gel is still fusible. This solid resin composition may be disintegrated to a pulverulent form and used as a molding .powder. Alternatively, then, a desirable polymer may be prepared by emulsifying the monomer or a syrupy polymer in an aqueous medium with or without a suitable emulsiflcatlon. agent such as polyvinyl alcohols, polyallyl alcohols, etc., and then polymerizing to the point where the gel precipitates. polymer may be separated and used as molding powder.

The solid forms of the fusible polymers may be used as molding compositions to form desirable molded products which may be polymerized to athermohardened state. Preferably, the molding is conducted in a manner such that the polymer fuses or blends together to form a substantially homogeneous product before the composition is polymerized to a substantially infusible state. This may be effected by conducting polymerization at an elevatedtemperature and/or pressure in the presence of benzoyl peroxide, generally in a heated mold. The polymers may be mixed with fillers such as alpha cellulose, wood pulp, and other fibrous substances, mineral fillers or pigments such as zinc oxide, calcium A polymer carbonate. lead chromate, magnesium carbonate, calcium silicate, etc.; plasticizers such as the saturated alcohol esters of maleic, fumaric, succinic, and adipic acids or dlor tri-ethylene glycol .bis(butyl carbonate). The polymeric molding powder'may be copolymerized with phenolic, cellulose acetate, urea, vinylic, protein, or acrylic resins. It is thus possible to produce transparent or opaque forms of a .wide variety of colors and hardnesses, depending upon the proper selection of the modifying agents.

+5 and C. The resulting mixture was washed with dilute hydrochloric acid and with water and purified by distillation in a vacuum. The resulting diethylene glycol bis(a1lyl carbonate) had an index of refraction (N of 1.4486, a density of (D420) of 1132-1140, and the following structure:

. The fusible polymers may be dissolved in suitable solvents, and used as coating and impregnat ing compositions. For example, the solutionof dispersion of fusible polymer in monomer or other organic solvent such as benzene, toluene, chloroform, acetone, dioxane, carbon tetrachloride, phenyl Cellosolve, dichlorethyl ether, dlbutyl phthalate, or mixtures thereof, is useful as a liquid coating composition. Objects of paper, metal,

CHFCHCH:0C=O 0=C0CH:CH=CH:

' -C:H4 O-C:Hr-

A quantity of 100 gms. of this compound was heated at 50 C. in a solution of 200 cc. of carbon tetrachloride with 2 percent benzoyl peroxide until the viscosity had increased about 200 percent. 500 cc. of methyl alcohol was added and a gummy polymer was precipitated. After filtering and dry g, a 5 gm. sample of the soft polymer was mixed with 5 percent benzoyl peroxide and pressed in a mold at a pressure of 2000 pounds per square inch at a temperature of 150 C. A hard, colorless, transparent polymer was produced.

' Example II Methallyl chloroformate was prepared by passing phosgene into 500 cc. of methallyl alcohol at a rate of 50-65 millimoles per minute. The mass 4 was stirred throughout the reaction and mainmonomer may be mixed directly with a suitable filler such as magnesium carbonate, cellulose pulp, asbestos, etc., in a ball mill or other mixing device. By proper selection of proportions, a dry pulverulent powder can be obtained which is capable of polymerization under, the influence of heat and pressure to a glossy solid polymer of high tensile strength.- The use of too much filler will cause a non-glossy finish and the use of too much monomer will make the powder moist and difiicult to handle. Sometimes it may be desirable to precure the molding powder by subjecting it to a moderate temperature, to 70 C. for

a limited period oftime, for example, one to three hours. This precuring operation is a partial polymerization and permits a dry molding powder where the same proportions of monomer might otherwise result ina moist molding composition. I

Further details of the synthesis of these new esters and of their applications will be apparent from the following examples.

. Example I Allyl chloroformate was prepared by placing 500 cc. of allyl alcohol in a flask equipped with a stirring device and bubbling phosgene through it at such a rate as would permit a rapid reaction without raising the temperature above 10 to 15 C. The flask was provided with an ice bath. when approximately a molar quantity of phosgene had been added, the reaction was discontinued and the crude material was permitted to stand at room temperature to separate the excess phosgene. washed, with water to remove the excess allyl alcohol and the allyl chloroformate was distilledin vacuum (B. P. 46-51 at 80 mm.).-

One mole'(l20 gms.) of allyl chloroformate was added slowly to 53 gms. of diethylene glycol and 100 gms. of pyridine. The chloroformate addition required about one-half hour during which time the reaction mass was maintained between The reaction mixture was tained at a temperature between 5C. and 10 C. by means of an ice bath. When approximately an equimolar quantity of phosgene had been absorbed, the reaction was stopped and the prodnot was washed with dilute hydrochloric acid and salt solution (NaCl). The methallyl chloroformate was distilled at 126-136" C. (760 mm.) 134 gms. of the chloroformate was added dropwise to 31 gms. 'of ethylene glycol and an excess gms.) of pyridine. The temperature was maintained below +10 C, during the reaction by means of an ice bathi. The ethylene glycol bis v(methallyl carbonate):

was distilled at 146 (2 mm). It had an index of refraction (N of 1.4489 and adensity of (DW) of 1.103.

A 100 gram sample of the monomer was diluted with 250 cc. of dioxane and heated'at 65 C. for 2 hours. The viscosity had increased appreciably but the mass was still liquid. A halfliter of.methyl alcohol was added to precipitate the fusible polymer, which was filtered and dried. The polymer wa a soft gummy material and after drying it was a non-viscid granular solid.

A five-gram sample was mixed with 5 percent benzoyl peroxide and pressed in a mold at 150 C.

and 2000 lb. per square-inch pressure. A colorless, transparent, solid polymer was formed.

Example III .One mole of glycerine (92 grams) was treated with phosgene at the rate of 50 millimoles per minute for 1 hours at a temperature of 0-10 stantial quantity of glycerol tris (crotyl carbonate) was produced, having the structure:

This ester polymerized upon heating with percent benzoyl peroxide at 70 C.

Example IV A sample of 120 grams oi methyl gly'cerine and 500 cc. of benzene was placed in a 2000 cc. flask with 250 grams of pyridine. While the mixture was being stirred, 350 grams or methallyl chloroformate were added at a rate sumciently slow to prevent the temperature from rising above 50 C. When the addition was completed, the water layer was separated and the oil layer was washed with dilute HCl and with water. The volatile impurities were removed by heating at 50-60 mm. total pressure. The ester was dissolved in 500 cc. benzol, and 5 grams of benzol peroxide was added. The mixture was heated at 50 C. for 3 hours; The viscous solution was poured into 1000 cc. of methyl alcohol and a large quantity of gelatinous polymer was precipitated. A five-gram sample of the dried polymer was mixed with 5 percent benzoyl peroxide. It was heated (160 C.) in a mold under 1500 pounds per square inch pressure. A hard, translucent, and nearly colorless solid was produced. The

monomer had the following structure:

Example V A quantity of glycerine (184 grams) was mixed with 7.8 moles of pyridine in a 3-liter flask equipped with stirrer and reflux condenser. 7.2 moles of allyl chloroformate were added at the rate of 100 millimoles per minute while the temperature was kept below +10 C. by an ice bath. When the reaction was completed, the mixture was permitted to stand overnight and thereby warm to room temperature. The ester mixture reaction was conducted at a temperature between 5 and 15" C. by adding the chlororormate slowly to a mixture of the other reagents. when the reaction was completed the mixture was permitted to warm to room temperature and was .waehed with dilute hydrochloric acid and twice with water and dried over calcium chloride.

A 2 gm. portion of the ester polymerized to a I hard transparent solid by heating to 140 C. with 3 percent benzoyl peroxide. The monomer has the following structure:

Example VII then treated with 100 gms. oiiallyl alcohol and 150 gms. of pyridine at a temperature between 5 and 15 C. as in previous examples. The ester was washed with dilute HCl and with dilute- NaaCOa. A five gram sample was heated with 5 percent benzoyl peroxide and a hard, brittle translucent solid was produced.

Example VIII A quantity of 200 grams'oi. glycerol tris (allyl q, carbonate) was partially polymerized by heating with 5 percentbenzoyl peroxide for 3 hours at C. The ester was thereby thickened to a viscoeity of about 500 percent greater than that oi the normal monomer.

A mold was prepared by separating two 15" x 15" sheets of polished plate glass with a x.

it" x 50" strip of Koroseal. The strip was laid around the edge or the plates about one inch in fnom the edge. The ends of the flexible strip were about 2 inches apart 'with the opening at one corner. The glass plates were clamped together with O clamps placed two inches apart around the periphery and pressing on the plates directly over the flexible gasket. The assembled mold was placed in a vertical position with the open corner uppermost.

The thickened monomer was poured into the mold and allowed to stand for ten minutes to separate the air bubbles. Th filled mold was then heated. for two hours at C. and the temperature raised gradually to C. over a period 01' two hours. The temperature was held at two hours and the mold was then removed from the mold and opened. During the heating the clamps were tightenedevery two hours to restore the pressure on the'polymer, the loss of which pressure was caused by the shrinkage ohthe gel. A

transparentand nearly was produced. a

1 Example IX Pentaerythritol tetrakia (allyl carbonate) w thickened by heating with 4 percent benzoyl peroxide for three hours at 65 C. The thickened monomer contained 2.8 percent residual peroxide. Three-hundred grams or the thickened monomer was mixed with grams or celcolorless sheet or resin ment in a porcelain ball mill with porcelain balls. The charged ball mill was placed in an oven at 70 C. and operated for 6 hours. when the prodnot was pulverized a uniform molding powder resulted.

A thirty gram sample was mixed with 2 percent benzoyl peroxide and pressed at 2900 pounds hours. A strong, uniform; light blue, solid polymer was produced.

Although the present invention has been described with respect to certain specific modifications, it is not intended that the details of these modifications shall be limitations upon the invention except as incorporated in the following claims.

This case is a continuation-in-part of Serial No. 361,280, filed October-"15, 1940, by Irving E. Muskat and Franklin Strain and Serial No. 403,- 703, filed July 23, 1941,3357 Irving 'E. Muskat and Franklin Strain.

We claim:

1. Glycerol tris (ally! carbonate).

2. Pentaerythritol tetrams (methallyl carbonate).

2,88%,128 lulose pulp and one gram of Chinese blue pig- 3. A polymer of lycerol tris (allyl carbonate).

4. A p o 1 y m e r of pentaerythritol tetrakis '(methallyl carbonate).

5. An ester having the structural formula:

"per square inch in a heated (125 C.) mold Zor 2 wherein R, is a saturated aliphatic hydrocarbon radical having a valence of :0, R1 is a radical corresponding to the radical R1 in the alcohol R105, said alcohol being an unsaturated monohydric alcohol having from 3 to 10 carbon atoms and having an olefinic bond between the beta and. gamma carbon atoms therein, and a: is a